2012 CENTRAL VALLEY 2012 CENTRAL VALLEY CHEMICAL SAFETY DAYCHEMICAL SAFETY DAY

Mechanical IntegrityMechanical Integrity

WHATWHAT’’S GOING ON S GOING ON INSIDE MY SYSTEM?INSIDE MY SYSTEM?

Mechanical IntegrityMechanical Integrity

GLOBAL OR DISTINCTGLOBAL OR DISTINCTGLOBALGLOBAL

DAILY ROUNDSDAILY ROUNDSTHE WALK THROUGHTHE WALK THROUGHEQUIPMENT INSPECTIONSEQUIPMENT INSPECTIONS--HOURLY OR BY HOURLY OR BY CALENDAR YEAR OR SEASONALCALENDAR YEAR OR SEASONALINTEGRITYINTEGRITYSAFETYSAFETYPLANNED MAINTENANCEPLANNED MAINTENANCEUNPLANNED MAINTENANCEUNPLANNED MAINTENANCE5 YEAR MECHANICAL INTEGRITY INSPT.5 YEAR MECHANICAL INTEGRITY INSPT.

GUIDELINES/REQUIREMENTSGUIDELINES/REQUIREMENTS

IIARIIARINDUSTRY STANDARDSINDUSTRY STANDARDSSITE DATASITE DATA--ONGOING AND ONGOING AND HISTORICALHISTORICALCODES AND LAWCODES AND LAW

A Simple Obtainable ExpectationA Simple Obtainable ExpectationTheThe

General Duty Clause RequirementsGeneral Duty Clause RequirementsThe owners and operatorsThe owners and operators of stationary sources producing, of stationary sources producing, processing, handling or storing such nasty substances:processing, handling or storing such nasty substances:

Have a general dutyHave a general duty toto identify hazards which may result from identify hazards which may result from such releases using appropriate hazard assessment techniquessuch releases using appropriate hazard assessment techniques

To design and To design and maintainmaintain a safe facilitya safe facility taking such steps as are taking such steps as are necessary to prevent releases, and to minimize the consequences necessary to prevent releases, and to minimize the consequences of accidental releases which do occur. of accidental releases which do occur.

Therefore We Must Create Usable, Workable Safety, Mechanical Therefore We Must Create Usable, Workable Safety, Mechanical Integrity and Training Programs!Integrity and Training Programs!

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General Duty Clause RequirementsGeneral Duty Clause RequirementsElements ofElements of designing and maintaining designing and maintaining a safe facility:a safe facility:

Be in compliance with good engineering practicesComply with recognized industry standardsFollow manufacturers’ recommendations for use and maintenance of equipmentBasic theory and system specific operator training

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DAILY ROUNDSDAILY ROUNDSMEET NORMMEET NORM

IS HE HIGH?IS HE HIGH? IS HE LOW?IS HE LOW?

OR IS HE JUST NORM?OR IS HE JUST NORM?

DAILY ROUNDSDAILY ROUNDS

USE ALL OF YOUR SENSES!USE ALL OF YOUR SENSES!LOOK LOOK

LISTEN LISTEN TOUCH TOUCH FEEL FEEL

SMELLSMELLTHINKTHINK

ANALYZEANALYZEACTACT

LOOK! NORM HIGH AND LOWLOOK! NORM HIGH AND LOWLEVELSLEVELSPRESSURESPRESSURESTEMPERATURESTEMPERATURESFROST PATTERNS/LINESFROST PATTERNS/LINESSWEAT LINESSWEAT LINESRUN TIMERUN TIMEON OR OFFON OR OFFCAPACITY CONTROLCAPACITY CONTROL

LISTEN AND FEEL!LISTEN AND FEEL!NOISENOISEVIBRATIONVIBRATIONHISSHISSTHUMPTHUMPDENTIST DRILLDENTIST DRILLWHAT IS NOT THE NORMWHAT IS NOT THE NORM

AND WE WONDER WHY THEY VISIT!

Typical Causes of FailureTypical Causes of Failure

Debris Debris embedded in embedded in the main valve the main valve Teflon VTeflon V--port port seatseatDebris in the Debris in the solenoid solenoid module module passagespassagesDebris packed Debris packed under Teflon under Teflon piston seal ringpiston seal ringLiquid slugs Liquid slugs damaging damaging pistonpiston

General Duty Clause General Duty Clause RequirementsRequirements

Elements ofElements of designing and maintaining designing and maintaining a safe facility:a safe facility:

Be in compliance with good engineering Be in compliance with good engineering practicespracticesComply with recognized industry standardsComply with recognized industry standardsFollow manufacturersFollow manufacturers’’ recommendations for recommendations for use and maintenance of equipmentuse and maintenance of equipment

International Institute of Ammonia International Institute of Ammonia RefrigerationRefrigeration ((IIAR)IIAR)

Ammonia Machinery Room Design (Bulletin #112)Ammonia Machinery Room Design (Bulletin #112)Suggested Safety and Op. Proc.Suggested Safety and Op. Proc.––Tie In (#107)Tie In (#107)Water Water ContamContam. in . in AmmAmm. . RefrigRefrig. Systems (#108). Systems (#108)IIAR Min. Safety IIAR Min. Safety CritCrit. for Safe . for Safe AmmAmm. . RefrigRefrig. (#109). (#109)StartStart--Up, Insp. and Up, Insp. and MaintMaint. of . of AmmAmm. . RefrigRefrig. (#110). (#110)Ammonia Machinery Room Ventilation (#11)Ammonia Machinery Room Ventilation (#11)IdentIdent. of . of AmmAmm. . RefrigRefrig. Piping & Component (#114). Piping & Component (#114)Avoiding Component Failure in Industrial Refrigeration Avoiding Component Failure in Industrial Refrigeration Systems Caused by Abnormal Pressure or Shock (#116)Systems Caused by Abnormal Pressure or Shock (#116)

American Society of Mechanical American Society of Mechanical EngineersEngineers (ASME )(ASME )

Boiler and Pressure Vessel CodeBoiler and Pressure Vessel CodePressure VesselsPressure VesselsNondestructive ExaminationsNondestructive Examinations

Refrigeration Piping CodeRefrigeration Piping Code

ANSI/ASHRAEANSI/ASHRAE

Standard 15 Standard 15 Safety Standard for Refrigeration SystemsSafety Standard for Refrigeration Systems

ASHRAE Chapters 3 & 6 ASHRAE Chapters 3 & 6 System Practices for Ammonia RefrigerantSystem Practices for Ammonia RefrigerantControl of Moisture and other ContaminantsControl of Moisture and other Contaminants

American National Standards American National Standards Institute and the Compressed Institute and the Compressed

Gas AssociationGas Association

ANSI K61.1 and CGA GANSI K61.1 and CGA G--2.12.1

Safety Requirements for the Storage and Safety Requirements for the Storage and Handling of Anhydrous Ammonia Handling of Anhydrous Ammonia

More of What We Look More of What We Look for for and and

What We See at What We See at FacilitiesFacilities

Mechanical Integrity Starts During The Mechanical Integrity Starts During The Installation and Continues For The Life Of Installation and Continues For The Life Of

The SystemThe System

IIAR Bulletin No.109, Section 4.9.7 states IIAR Bulletin No.109, Section 4.9.7 states that that pressure relief devicespressure relief devices should be should be replaced within five yearsreplaced within five years of the date of of the date of manufacture, or by the date specified by manufacture, or by the date specified by the manufacture. the manufacture.

EPA Ammonia EPA Ammonia RegulationRegulation

and Findingsand Findings

Bradley MillerBradley MillerEPA, Region 8EPA, Region 8

IIAR Bulletin No. 112, IIAR Bulletin No. 112, Ammonia Machinery Ammonia Machinery RoomRoom DesignDesign: Section 4.3.f requires all : Section 4.3.f requires all ammonia vessels, equipment and piping to ammonia vessels, equipment and piping to be labeledbe labeled. Identification of piping should . Identification of piping should include descriptive labels and flow include descriptive labels and flow direction. direction.

Hey Joe Close Valve 32AHey Joe Close Valve 32AHurry ItHurry It’’s a Bad Leak.s a Bad Leak.

ANSI /ASHRAE Standard 15ANSI /ASHRAE Standard 15--2001, 2001, Safety Safety StandardStandard for Refrigeration Systemsfor Refrigeration Systems, , Section 9.4.3. requires that facility piping Section 9.4.3. requires that facility piping have have hydrostatic pressure relief valveshydrostatic pressure relief valves in in sections of piping in which liquid ammonia sections of piping in which liquid ammonia could be isolated between shutcould be isolated between shut--off valves. off valves.

IIAR Bulletin No. 110, IIAR Bulletin No. 110, StartStart--up, Inspection up, Inspection and Maintenance of Ammonia Mechanical and Maintenance of Ammonia Mechanical Refrigerating SystemsRefrigerating Systems Section 6.8 Section 6.8 requires facilities to have requires facilities to have rapid closing rapid closing valves at all oil draining pointsvalves at all oil draining points. .

Mechanical Integrity???!!!???Mechanical Integrity???!!!???

Corrosion Corrosion and and

Breaches of Vapor BarriersBreaches of Vapor Barriers

PipePipe

Pipe Pipe showing showing rupturerupture

22”” Pipe Pipe –– Wall ThicknessWall Thickness

Schedule 40 Schedule 40 ––0.1540.154””At cut At cut ––0.11230.1123””27% loss27% lossAt rupture At rupture ––0.05630.0563””63% loss63% lossThickness at Thickness at pit bottoms pit bottoms even lesseven less

IIAR Bulletin No.109;IIAR Bulletin No.109; Minimum Safety Minimum Safety Criteria for a SafeCriteria for a Safe Ammonia Refrigeration Ammonia Refrigeration SystemSystem; Sections 4.7.4 & 4.7.5 requires:; Sections 4.7.4 & 4.7.5 requires:

UninsulatedUninsulated refrigerant refrigerant pipe that is corrodedpipe that is corroded is is to be replaced or cleanedto be replaced or cleaned to bare pipe to bare pipe and and painted,painted,Insulated pipingInsulated piping showing signs of vapor showing signs of vapor barrier failure should have the barrier failure should have the vapor barrier vapor barrier removed and the pipe inspectedremoved and the pipe inspected. If corrosion . If corrosion is found, it should be treated as above.is found, it should be treated as above.

EPA, Region 8 RequirementEPA, Region 8 Requirement

Areas of piping and equipment located Areas of piping and equipment located throughout the facility had ice buildthroughout the facility had ice build--up, apparent up, apparent insulation vapor barriers breached, visible pipe insulation vapor barriers breached, visible pipe corrosion, and other conditions that did not corrosion, and other conditions that did not appear to comply with industry standards (IIAR appear to comply with industry standards (IIAR Bulletin No.109;Bulletin No.109; Minimum Safety Criteria for a Minimum Safety Criteria for a SafeSafe Ammonia Refrigeration SystemAmmonia Refrigeration System; Sections ; Sections 4.7.4 & 4.7.5). 4.7.4 & 4.7.5). The facility shall inspect all The facility shall inspect all piping and equipment and certify that it is fit piping and equipment and certify that it is fit for service.for service.